Power generation container with additional improvements

ABSTRACT

An improved power generation container providing improved access and installation and removable of components by using modular components. A self bailing and self-aligning exhaust system is further provided.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application is a continuation-in-part application of U.S. patent application Ser. No. 14/277,044, filed on May 13, 2014, which claims priority and benefit of U.S. provisional patent application having application No. 61/822,911, filed on May 13, 2013, and entitled “Power Generation Container Improvements.” All of the patent applications referenced immediately above in this paragraph are hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to mobile containers for housing power generation machinery or stations, and more particularly, to semi-tractor trailer containers incorporating improvements for housing and accommodating power generation machinery.

2. Description of Related Art

Mobile power generation systems capable of delivering megawatts of power are known to offer certain advantages compared to power delivered from an electrical utility power distribution grid. Mobile power generation systems can provide power as needed at times of peak demand or during brownout in a distribution grid, or during an emergency caused by a failure in the distribution grid. A mobile power generation system can be located at places distant from a distribution network where there is need for power, thus minimizing any delay or the need or expense for constructing power lines to distant or remote places.

The conventional method of transporting a mobile power station is to mount an industrial electric generator to the floor within a trailer or a stackable shipping container which is placed on a semi tractor trailer. Power generators are conventionally secured to the floor of a shipping container or semi trailer by aligning mounting holes of the generator to corresponding mounting apertures on the floor of the shipping container or semi trailer. Given the size and weight of industrial generating equipment, it can be very difficult to align mounting holes of the generating equipment with the mounting apertures in the floor. Furthermore, the mounting holes of generating equipment do not always align perfectly with the mounting apertures on the trailer floor, thus further complicating the mounting process. Additionally, the substantial weight of industrial equipment requires the floors mounting such equipment to be structurally reinforced to support such weight. Industrial generating equipment also can have some spillage of oil, fuel, coolant, and other fluids. When these fluids escape from the generating equipment, the fluids simply spill onto the floor, creating dangerous conditions for operators and maintenance personnel. U.S. Pat. No. 9,051,011, which is hereby incorporated by reference, discloses improvements for mounting industrial equipment to the floors of shipping containers or semi-tractor trailers.

In addition to the need for improved floor mounting systems in such power generation containers, there also are needed improvements in facilitating access to the power generating machinery inside the containers, container exhaust systems, and mounting fixtures on the containers.

ASPECTS AND SUMMARY OF THE PRESENT INVENTION

One aspect of the present invention is to facilitate and provide greater access to power generation machinery inside power generation containers.

Another aspect of the present invention is to provide improved mounting fixtures for power generation containers that can be more easily painted, cleaned, and modified.

A further aspect of the present invention is to provide improved exhaust and ventilation systems for power generation containers.

An additional aspect of the present invention is to provide easy access ladders for maintenance on the roof of power generation containers.

In order to achieve the above aspects and more, the present invention provides an improved power generation container providing improved access and installation and removable of internal machinery by using modular components. A self bailing and self-aligning exhaust system is further provided.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a self-bailing door frame configured in accordance with the present invention;

FIG. 1a is a perspective view of an estop receptacle configured in accordance with the present invention and mounted on the self-baling door frame of FIG. 1;

FIG. 1b is a perspective view of an estop blank plate configured in accordance with the present invention and mounted on the self-bailing door frame of FIG. 1;

FIG. 1c is a perspective view of a removable center post configured in accordance with the present invention for the self-bailing door frame shown in FIG. 1.

FIG. 1d is an enlarged view of the self-bailing door frame shown in FIG. 1;

FIG. 1e is another perspective view of the self-bailing door frame shown in FIG. 1;

FIG. 1f is an enlarged view of the removable center post shown in FIG. 1 c;

FIG. 1g is an enlarged view of the estop receptacle shown in FIG. 1 a;

FIG. 1h is an enlarged view of the estop receptacle shown in FIGS. 1a and 1g , wherein a cover plate is included over the estop receptacle;

FIG. 1i is an exploded view of the estop receptacle and cover plate shown in FIG. 1 h;

FIG. 1j is an enlarged view of the estop blank plate shown in FIG. 1 b;

FIG. 1k is an enlarged view of the estop blank plate shown in FIGS. 1b and 1 j;

FIG. 1L is an enlarged rear view of the removable center post shown in FIGS. 1c and 1 f;

FIG. 1m is an enlarged view of the bottom of an end of the removable center post shown in FIG. 1L;

FIG. 2 is a perspective view of a dual door assembly configured in accordance with the present invention;

FIG. 2a is a perspective view of a door latch configured in accordance with the present invention;

FIG. 2b is an enlarged view of the dual doors shown in FIG. 2;

FIG. 2c is an enlarged view of one of the duel doors shown in FIGS. 2 and 2 b;

FIG. 2d is an enlarged view of the door latch shown in FIG. 2 c;

FIG. 2e is an exploded rear view of the door latch shown in FIG. 2 d;

FIG. 3 is a perspective view of a self-bailing roof exhaust system configured in accordance with the present invention;

FIG. 3a is an exploded view of the self-bailing roof exhaust system shown in FIG. 3;

FIG. 3b is a perspective view of the heat sink shown in FIG. 3;

FIG. 3c is a perspective view of the non-heat conductive ring shown in FIG. 3;

FIG. 3d is a perspective view of the exhaust adapter assembly shown in FIG. 3;

FIG. 3e is a perspective view of the flange clamp shown in FIG. 3;

FIG. 3f is an exploded view of the exhaust adapter assembly shown in FIG. 3 including exhaust bellows;

FIG. 3g are additional views of the self-bailing roof exhaust system shown in FIG. 3 including the lower exhaust bellow;

FIG. 4 is a perspective view of a storable ladder configured in accordance with the present invention;

FIG. 4a is a perspective view of the ladder shown in FIG. 4;

FIG. 4b is a perspective view of the ladder receptacle shown in FIG. 4;

FIG. 4c is an enlarged perspective view of the folding bar shown in FIG. 4;

FIG. 5 is a perspective view of a removable front wall of a power generation container configured in accordance with the present invention;

FIG. 5a is a perspective view of the end frame shown in FIG. 5;

FIG. 5b is an enlarged view of the removable air intake louver shown in FIG. 5;

FIG. 5c is an enlarged view of the front wall shown in FIG. 5;

FIG. 5d is an exploded view of a ventilation system configured in accordance with the present invention;

FIG. 5e is an enlarged view of the radiator section of the power generation container shown in FIG. 5d , wherein the radiator panels and roof ventilation have been removed;

FIG. 5f is an enlarged view of the removable frame of the roof of the radiator section of the power generation container shown in FIG. 5 d;

FIG. 5g is an enlarged view of the air discharge screen supported by the removable from on the roof of the radiator section of the power generations container; and

FIG. 5h shows exploded views of the ventilation system shown in FIG. 5 d.

The foregoing has outlined, rather broadly, the preferred features of the present invention so that those skilled in the art may better understand the detailed description of the invention that follows. Additional features of the invention will be described hereinafter that form the subject of the claims of the invention. Those skilled in the art should appreciate that they can readily use the disclosed invention and specific embodiments as a basis for designing or modifying other structures for carrying out the same purposes of the present invention, and that such other structures do not depart from the spirit and scope of the invention in its broadest form.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the drawings, FIG. 1 illustrates a door frame 10 for a self-bailing door assembly to be located on the side of a power generation container, such as a semi-tractor trailer. Self bailing refers to the ability to directly receive or accumulate rain water without it entering the power generation container. The self-bailing achieved by specific gravity, all components fit from under another component with the bottom being sealed and self-draining the exterior. The frame 10 includes an outer rim or outer panel 12 that preferably are weld together at the corners 13 to form a rectangular configuration. The frame 10 houses and mounts the dual door assembler 14 shown in FIG. 2. A removable center post 16 shown in FIG. 1c is secured within the frame 10 by fitting one end of the post 16 within a slot 18 in the top of the frame 10, and the other end of the post 16 in a notch 20 in the base or bottom of the frame 10. The frame 10 preferably is constructed of a metal, such as steel.

FIG. 1a illustrates an estop receptacle 22 mounted to the outer rim 12 of the frame 10. The estop receptacle 22 houses components for an emergency stop button for a power generation system to be contained within the power generation container.

FIG. 1b illustrates a flat blank plate 24 for covering an unused port or aperture for mounting an estop receptacle 22. The blank plate 24 preferably is constructed of metal and can be easily removed or replaced for adding or removing an estop receptacle 22.

In accordance with the present invention, the estop receptacle 22 can be easily added or removed from estop ports or apertures 37. Moreover, the estop receptacle 22 can be pre-wired and installed on any outer surface of a container by simply making an aperture in the container for the wiring to pass through, and the bolting or welding the estop receptacle to the outer surface of the container. This feature of the present invention enables estop receptacles to be easily added to desired upper locations when a container is on the ground, or located in a lower location when a container is located at a higher location, such as when on a semi-trailer, or at multiple estops at multiple locations. A blank plate 24 can easily cover an unused estop port 21. By enabling estop receptacles 22 to be easily removed and repositioned to a preferred located, this reduces the cost of having to provide multiple estop receptacles 22 for various potential locations.

Additionally, enabling the estop receptacle to be added or removed allows the estop receptacle to be easily painted and cleaned, thus preventing rust and dirt built up. The numeral intricate structures and fixtures located within the estop receptacle make it very difficult to paint and clean when mounted, this leading to rust and corrosion. By enabling the estop receptacle 22 to be painted completely before being mounted by submerging in it in paint, enables the estop receptacle to be completely covered by paint and thoroughly protected from rust and corrosion. Moreover, the estop receptacle 22 can be removed for easy cleaning or repainted if needed. It the estop receptacle was welded to the container wall, as is conventionally, done such thorough cleaning or painting would not be possible.

FIG. 2 illustrates a dual door assembly 14 configured in accordance with the present invention for mounting within a door opening of a power generation container.

FIG. 2a is an enlarged view of the door latch configured in accordance with the invention shown in FIG. 2.

FIG. 1d is an enlarged view of the frame 10 shown in FIG. 1. In addition to the rim or outer frame 12, illustrated are the upper slot 18, preferably formed by a curved U-bar mounted to any inner frame or rim 27, and the notice 20 formed between two bars or rods 17. Screw holes 23 are located within the end of the bars 17 for securing the bottom end 19 of the removable post 16 within the notch 20. A spacer wall 11 is located between and perpendicular to the inner rim 27 and the outer rim 12. Mounting holes 25 are located within the outer rim 12 for securing the frame 10 within an opening in the side of a power generation container. FIG. 1e provides another perspective view of the frame 10.

FIG. 2b illustrates the dual door assembly 14, and FIG. 1f illustrates the removable center post 16 which is located between the doors 31 and 33. The dual door assembly 14 including the removable post 16 are to be located within an opening in the side of a power generation container in order provide easy access to the power generation machinery contained inside. The doors 31,33 each include a door latch 30 and mounting hinges 32, On the opening side of the door are included door latches 34.

FIG. 1g illustrates an enlarged view of the estop receptacle 22 bolted to the rim 12 of the frame 10 shown in FIG. 1.

FIG. 1h is a detailed view of the estop receptacle 22 including a cover plate 36 bolted to the rim 12 of the frame 10 shown in FIG. 1. The 152 E-Stop outside body (top) receives 154 E-Stop mounting plate and 155 front cover mounting plate and are aligned by means of slot and tang construction with 152 E-Stop outside body (bottom) clamping them by means of 158 E-Stop mounting bolts, 160 E-Stop Mounting washers and 162 E-Stop mounting nuts. 152 E-Stop outside body is connected to 150 Mounting frame Stud and 160 E-Stop Mounting washers and 162 E-Stop mounting nuts. 156 front cover is mounted to 155 by means of 157 front cover mounting bolts. The pre wired E-Stop Switch is mounted to 154E-Stop mounting plate by means of 157 front cover bolts in 172 riv-nuts. 164 Rear electrical cover with be mounted to 152 by means of 166 Rear electrical cover bolts and 168 Rear electrical cover washers through 170 Rear electrical cover mounting holes into 152 E-Stop outside body by means of 172 riv-nuts.

FIG. 1i is an exploded view of the estop receptacle 22 and cover plate 36 mounted to the rim 12 of the frame 10. An aperture 37 in the rim 12 of the frame 10 is shown for receiving wiring from electrical components to be mounted within the estop receptacle 22. The estop receptacle is modularly constructed of symmetrical parts, so that they can easily be replaced and minimize cost by using minimal similar parts.

FIG. 1j is an enlarge view of the blank plate 24 covering an unused estop mounting aperture 37 on the outer rim 12 of the frame 10. Bolts 21 mount blank plate 24 to the outing rim 12 of the frame 10.

FIG. 1k is an enlarged view of the black plate 24 shown in FIGS. 1b and 1 j. Bolts 21, nuts 37, and washers 39 are shown securing the blank plate 24 to the outer rim 12.

FIG. 1L is an enlarged view of the removable center post 16 shown in FIG. 1c . Edges 40 are formed in the front 41 of removable center post 16 for receiving the corner edges of the doors 31,33 when is the closed position. Apertures 42 are located in the sides of both the top end 44 and the bottom end 19 of the post 16 for securing the post 16 into a secured position within the frame 10.

FIG. 1m is an enlarged view of the rear 45 and bottom end 19 of the removable center post 16. The top end 44 and the bottom end 19 of the post are identical, so it does not matter which end is first inserted into the slot 18 of the frame 10 when securing the post 16 in place. Also illustrated are the other side of the edges 40. Nuts or bolts 43 are shown for securing the bottom end 19 of the post 16 within the notch 20 of the frame 10 when mounting the post 16 in place.

FIG. 2c is an enlarged view of door 33 shown in FIG. 2b . Illustrated are the hinges 32, door latch handle 30, and release latches 34. FIG. 2d is an enlarged view of the door latch 30 shown in FIG. 2 c.

FIG. 2e is an exploded rear view of the door latch 30 shown in FIG. 2d . The outside handle 101 is mounted to the lockable outside handle base 102 and to the door 33 by mounting bolts 36 and outside mounting nuts 37. The symmetrical door rod assembly 103 is mounted to the door 33 by the symmetrical control with safety escape handle mounting screws 39. The handle 101 rotates the square shaft 35 through the lockable outside handle base 102, the boomerang clocking mechanism 38, the symmetrical door rod control with safety escape handle 104, the safety handle 105, the normal control rod actuator 108, while rotating the inside door handle 107. The rotation of said square shaft is clocked by boomerang clocking mechanism 38 about the single mounting bolt 36, and this clocking can be reversed by flipping the boomerang clocking mechanism 38 because it has reversed geometry. The square shaft 35 rotates the normal door rod control 108 to engage perpendicular actuator pins 110 that move the door rod actuators 106 to unlatch the door release latches 34. The safety escape handle 105 can rotate independently of said square shaft 35 to engage perpendicular actuator pins 110 in the symmetrical door rod control with safety escape handle 104 that moves the door rod actuators 106 to unlatch the door latches 34 in the event that the door 33 becomes locked from the outside. The safety escape handle 105 can still open the door 33 from the inside. Additionally, the reverse geometry design of the components shown in FIG. 2e of the latch 30 enable this design to work on either a left or right opening door, simply by reversing the components of the latch 30

FIG. 3 is a perspective view of an exhaust adapter assembly 50 configured in accordance with the present invention. The exhaust adapter assembly 50 is designed to be located on the roof or top of a power generation container housing power generation machinery. Illustrated is a metal pan 52 including an integral drain 54. The sides 53 of the pan 52 prevent water on the roof of the power generation container from flowing into the base area 54 of the exhaust adapter assembly 50. The drain 55 enables rain water failing into the base area 54 to flow off the base area 54. Thus, this design prevents rain water surrounding the exhaust from flowing into the exhaust 51.

FIG. 3a is an exploded view of the exhaust adapter assembly 50 illustrated in FIG. 3. Illustrated are fastening bolts 57, rotatable split flange clamp 58, exhaust adapter assembly 56, heat seat member 59, mounting member 61, and mounting bolts 62. In accordance with the present invention, the exhaust adapter assembly 56 mounts to the heat sink member 59, which is then mounted to the mounting member 61. The rotatable split flange clamp 58 mounts to exhaust bellows 120 (FIG. 3f ), and the rim 60 of the exhaust adapter assembly 56 fits inside the inner rim and ledge 65 of the rotatable split flange clamp 58, thus enabling the exhaust bellows 120 to rotate freely and adjust by rotating the rotatable split flange clamp 58 relative to the exhaust adapter assembly 56 and its upper rim 60.

FIG. 3b illustrates the exhaust adapter assembly of FIG. 3 with only the pan 52 and mounting member 61 illustrated.

FIG. 3c is an enlarged view of the heat sink member 61. The heat sink member 61 preferably is a glass fiber gasket made by good quality high temperature resistant and high strength glass fiber cloth, coating with Nonmetal rubber or fluorine. Through a special process pressing and cutting, the heat sink member is high temperature resistant, thermal insulated, fireproofed, corrosion resistance, ageing resistance, and has a high strength and smooth appearance.

FIG. 3d is an enlarged view of the exhaust adapter assembly 56. Included in the exhaust adapter assembly are mounting holes 121 and an upper rim 60 configured to rotate freely inside the rotatable split flange clamp 58 mounted to the exhaust bellows 120. The lower rim 122 is bolted to the heat sink member 61 and then the mounting member 61. The mounting member 61 is a metal gasket welded to the base 54 of the pan 52 of the exhaust adapter assembly 50.

FIG. 3e is an enlarged bottom view of the rotatable flange clamp 58 shown in FIG. 3. Also shown are mounting holes 123 for bolting the rotatable flange to the exhaust bellows 120.

FIG. 4 illustrates a storable foldable ladder assembly 70 configured in accordance with the present invention. Illustrated are the straight ladder 72 located within a receptacle 74. The receptacle 74 is to be mounted to the outer side of a power generation container. The ladder 72 is mounted to the receptacle 74 by rotatable bars 75 that each are pivotally mounted to the ladder 72 and the receptacle 74. The ladder 72 is rigid and includes rungs 71 between the sides 73 of the ladder 72. Clasps 76 hold the ladder 72 in place within the receptacle 74 is the closed position.

FIG. 4a illustrates the ladder 72. Apertures 77 located near the top and bottom on the sides 73 of the ladder 72 are used for bolts 78 to pivotally mount the ladder 72 via the bars 75 to the receptacle 74. FIG. 4b illustrates the receptacle 74 containing pivotally mounting bracket 80 having apertures 81 for pivotally mounting the bars 75 using bolts 78. FIG. 4c illustrates the pivoting bar 75 shown in FIG. 4 for rotatably mounting the ladder 72. The bar 75 includes pivotally mounting holes 82,83 for pivotally mounting the ladder 72 to the receptacle 74 using bolts 78.

In accordance with the present invention, the ladder 72 is contained within the receptacle 74 is the closed and used position. When a person wants to access the roof of a power generation container including the ladder assembly 70, the person simply releases the ladder 72 for the clasps 76 and rotates the ladder down and outward from the receptacle 74. The lock bar 84 of the bar 75 prevents the bar 75 from rotating past a 90 degree angle from the side of a container, thus keeping the ladder away from the receptacle 74 in the open position. When the user is down with the ladder 72, the user simply pushes the ladder back up and inside the receptacle 74 and locks the ladder 72 within the receptacle 74 using the clasp 76.

FIG. 5 illustrates a power generation container 90 configured in accordance with the present invention. In accordance with the present invention, the front end 91 of the container 90 is removable to provide greater and easier access to the contents therein, such as the fuel tank 92 and gen set. The front end 91 of the container 90 includes a gooseneck end frame 95, a removable air intake louver 93, and a front wall 94.

FIG. 5a illustrates the gooseneck end frame assembly 95. FIG. 5b illustrates an enlarged view of the front louver 93. FIG. 5c illustrates an enlarged view of the removable front wall 94 which preferably is bolted to the gooseneck end frame 95 for easy removal and attachment.

FIG. 5d is a perspective view of the rear end of the container 90 shown in FIG. 5, wherein the radiators for the power generation machinery are typically located. Illustrated are the adjustable exhaust assembly 50 and the foldable ladder assembly 70.

Also illustrated are the dual doors 31 and 33. In accordance with the present invention, louvers (not shown) on the sides 96 of the container 90 are removable to provide greater and easier access to the radiator section and machinery contained therein, such as the radiator machinery.

In accordance with a further aspect of the present invention, the roof on the rear end 97 of the container 90 can be removed to allow the radiator machinery, or other machinery, to be lowered or raised via the opening 98 in the roof of the container 90 by removing modular components, such as the anti racking frame 99 and the air discharge screens 100. The screen 100 is secured and removed from the frame 99 by using mounting hardware, such as bolts, and the frame 99 is similarly attached and removed from the top of the container 90.

FIG. 5e is an enlarged view of the rear 15 of the container 90 showing the modular components of the frame 99 and the screen 100 removed from the roof of the container 10 to provide greater access to the machinery inside, and raise or lower machinery via the roof of the container 90. Rear doors 102 also provide access to the machinery within the rear 15 of the container 10.

FIG. 5f is an enlarged view of the anti-racking frame 99, and FIG. 5g is an enlarged view of the screen 100.

While specific embodiments have been shown and described to point out fundamental and novel features of the invention as applied to the preferred embodiments, it will be understood that various omissions and substitutions and changes of the form and details of the invention illustrated and in the operation may be done by those skilled in the art, without departing from the spirit of the invention. 

1. A self-bailing and self-adjusting exhaust system for a container for a power generation system, comprising: a rimmed pan an exhaust adapter assembly; and a drain in the pan. 